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RMA - 14

5 days

Doha

3 September, 2023

11900 QAR

Root Cause Failure Analysis (RCFA)

Course Overview:

This Root Cause Failure Analysis training course will enable delegates to remain abreast of the latest researched trends, techniques and strategies to improve the condition and performance of their operational process. This hands-on intervention will equip you with the necessary basic knowledge and skills to optimize the function, daily running, and maintenance of the five main aspects of the process.

RCA practice aims to solve problems by attempting to identify and correct the root causes of events, as opposed to simply addressing their symptoms. By focusing correction on root causes, problem recurrence can be prevented. RCFA (Root Cause Failure Analysis) recognizes that complete prevention of recurrence by one corrective action is not always possible.

Root cause analysis is not a single, sharply defined methodology; there are many different tools, processes, and philosophies for performing RCA. Most of RCA tools are also use as Risk Analysis and Management Tools.

In our course we will present clear understanding of different RCA tools, sequences and undergo exercises that will pave the road for immediate application for the RCA concepts into your everyday operations.

Course Objectives:

By the end of this training, participants will be able to:

To understand the basics of RCA and its relation to modern maintenance
To understand the difference between failure modes, failures and failure effects
To understand the difference between sporadic, chronic and cascading failures
To present in theory and practice through exercises the different RCA tools
To relate RCA analysis and tools to other maintenance methodologies
Present Actual case studies of complex situations
Demonstrate several software tools of different capabilities to assist in RCA application

Who Should Attend?

This course is ideal for maintenance managers, operations managers and reliability professionals. Maintenance engineers, experienced supervisors, planners and functional specialists will also benefit greatly from this course.

Course Contents:

Module (01) Concept of Failure

Machine Failure
Types of Failure Causes
Effect of Failure
Failure Cascading
Failure Modes
Chronic vs. Sporadic Problems

Module (02) Root Cause Failure Analysis process

What RCFA is?
Types of Root Causes
Process of RCA – Generic Steps in an RCFA
Challenges in Setting up RCFA

Module (03) Basic pre-RCA tools

Problem definition
Process definitions
Process Mapping – Flow chart
SIPOC
Data collection tools
Essential statistics

Module (04) RCA tools: Prioritization – FMEA Failure Modes & Effects Analysis

Failure Analysis Methods
Risk Priority Number – RPN
Implementing FMEA
FEMA examples and exercises

Module (05) Understanding and Investigation

5 Whys technique
The Ishikawa Diagram
Fault Tree Analysis – FTA
Pareto Charts
Tools analysis and exercises’ results discussions

Module (06) Lean Six Sigma in RCA

Visual Management: 5S
The effect of losses/waste
Value Stream Mapping
The effect of inconsistency
Detecting wastes through DOWNTIME tool
DAMIC process

Module (07) Decision Making methodologies

What is a Decision
Financial methods
Operational methods

Module (08) Case studies and SW tools

Dust Explosions RCA
Assignment case studies discussion
SW package samples

Module (09) Assessment and continuous improvement through KPIs

Introduction to KPIs
Choosing KPIs
Measuring the O & M Program effectiveness

Course Summary & Conclusion

Root Cause Failure Analysis (RCFA)

TRAINING PLAN FORM